US2005143512A1PendingUtilityA1

Attenuation material

Priority: Mar 29, 2000Filed: Mar 29, 2001Published: Jun 30, 2005

Est. expiryMar 29, 2020(expired)· nominal 20-yr term from priority

Inventors:John Bryant

C08L 23/16C08K 3/34C08L 2207/24C08L 17/00C08K 3/04

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Claims

Abstract

An attenuation material and a method of making such an attenuation material. The attenuation material includes a matrix of elastomer having mixed therewith particulate vulcanised rubber and particulate magnetisable material, the mixture being substantially free of sublimable foaming agents.

Claims

exact text as granted — not AI-modified

1 . An attenuation material comprising a mixture, the mixture comprising a matrix of elastomer having mixed therewith a particulate vulcanised rubber and a particulate magnetisable material, the mixture being substantially free of sublimable foaming agents.

2 . The attenuation material according to claim 1 , wherein the mixture further comprises a filler material.

3 . The attenuation material according to claim 2 , wherein the filler material comprises at least one of particulate carbon black, particulate clay, particulate limestone, particulate silica and finely divided paper.

4 . The attenuation material according to claim 2 or 3 , wherein the filler material comprises a finely divided form having a particulate size in the range of from about 50 to about 500 microns.

5 . The attenuation material according to claim 3 , wherein the particulate silica comprises waste silica.

6 . The attenuation material according to claim 1 , wherein the magnetisable material comprises a ferrous material.

7 . The attenuation material according to claim 1 , wherein the magnetisable material comprises at least one of millscale, copper silicate and Fe 3 O 4 .

8 . The attenuation material according to claim 1 , wherein the magnetisable material comprises a finely divided form.

9 . The attenuation material according to claim 8 , wherein the magnetisable material has a particle size of about 300 microns.

10 . The attenuation material according to claim 1 , wherein the magnetisable material and a filler are present in a ratio of about 4 to 1 by weight.

11 . The attenuation material according to claim 1 , wherein the vulcanised rubber comprises discrete particles.

12 . The attenuation material according to claim 1 , wherein the vulcanised rubber is substantially free of reaction with the elastomer when the elastomer is cured.

13 . The attenuation material according to claim 1 , wherein the particulate vulcanised rubber is obtained cryogenically, by comminution of waste rubber compounds.

14 . The attenuation material according to claim 13 , wherein the waste rubber compounds comprise at least one of natural rubber and SBR.

15 . The attenuation material according to claim 1 , wherein the vulcanised rubber comprises comminuted rubber tires, the comminuted rubber tires comprising at least one of waste and worn tires.

16 . The attenuation material according to claim 1 , wherein the vulcanised rubber is in a finely divided form.

17 . The attenuation material according to claim 16 , wherein the vulcanised rubber has a particle size of less than about 500 microns.

18 . The attenuation material according to claim 1 , further comprising at least one fire retardant material.

19 . The attenuation material according to claim 1 , further comprising an adhesion enhancing material.

20 . The attenuation material according to claim 19 , wherein the adhesion enhancing material is added in the ratio of about 50 parts per 100 of the matrix of elastomer, by weight.

21 . The attenuation material according to claim 1 , wherein the matrix of elastomer includes at least one of the following batch ingredients:
(A) KELTAN; (B) SPHERON 5000A Medium Fine Carbon Black; (C) Zinc Oxide Active; (D) Stearic Acid; (E) PEG 4000; (F) Britomya BSH 20; (G) Flexon 815 Liquid; (H) KEZADOL GR; (I) RHENOGRAN 580 Sulphur; (J) RHENOGRAN TMTD 80 Tetramethylthiuram Disulphide; (K) RHENOGRAN MBT 80 Mercaptobenzothiazole; and (L)RHENOGRAN MBTS 80 Benzothiazyl Disulphide.

22 . The attenuation material according to claim 1 , wherein the elastomer is substantially free of at least one of a natural rubber and an SBR.

23 . The attenuation material according to claim 1 , wherein the elastomer comprises at least one of polyolefin type rubber and EPDM.

24 . The attenuation material according to claim 1 , wherein the matrix of elastomer, the vulcanised rubber and the magnetisable material are present in a ratio in a range of from about 100:20:20 to about 100:50:50.

25 . An attenuation material comprising a composition comprising at least one of matrix A, matrix B, matrix C and matrix D, wherein matrix A, matrix B, matrix C and matrix D comprise:

Matrix A
Matrix B
Matrix C
Matrix D

Keltan 314
2.4000
2.4000
2.4000
2.700

Keltan 4903
9.6000
9.6000
9.6000
10.6000

Zinc Oxide Active
0.3500
0.3500
0.3500
0.3900

Stearic Acid 1800
0.1200
0.1200
0.1200
0.1300

PEG 4000
0.1200
0.1200
0.1200
0.1300

TE 80 Powder
0.2000
—
—
—

STUKTOL W816
0.2000
—
—
—

Baco Superfine 7
14.8000
—
—
—

Spheron 5000A
2.0000
16.8000
16.8000
18.7000

Britomya BSH 20
4.8000

4.8000
5.3000

Flexon 815 Liquid
8.8000
8.8000
8.800
9.800

KEZADOL GR
0.5000
0.5000
0.500
0.5600

Rhenogran CTP80(PVI)
0.0900
0.0900
0.090
0.1000

RHENOGRAN 580
0.1100
0.1100
0.1100
0.1200

RHENOGRAN
0.8800
0.0800
0.0800
0.0900

TMTD 80

RHENOGRAN MBT 80
0.0270
0.0270
0.0270
0.0300

RHENOGRAN
0.0900
0.0900
0.0900
0.1000

MBTS 80

XETAL Filler A
13.0000
13.0000
13.000
9.7000

Vulcanised Rubber

XETAL Filler B Mill
21.6000
30.3000
13.00
9.7000

scale, copper silicate

or Fe 3 O 4

Total Weight (kg)
78.8871
87.1871
69.8871
68.1500

26 . A method of manufacturing a material suitable for use as an attenuation material, the method comprising:
1) providing a mixture comprising a matrix of elastomer having mixed therewith particulate vulcanised rubber and particulate magnetisable material, the mixture being substantially free of sublimable foaming agents; and 2) forming the mixture into at least one sheet.

27 . The method according to claim 26 , wherein at least the magnetisable material and the vulcanised rubber are mixed together prior to further mixing with the elastomer, prior to curing or vulcanisation of the elastomer.

28 . The method according to claims 26 or 27 , wherein the further mixing is typically carried out in a mixer, the mixer comprising a Banbury rotor type mixer.

29 . The method according to claim 28 , wherein the mixer has a rotor speed in the range of from about 60 to about 100 rpm.

30 . The method according to claim 26 , wherein the vulcanised rubber is not added to the elastomer after the addition of the magnetisable material.

31 . The method according to claim 26 , wherein the mixture in step 1) is mixed for about 4 to about 12 minutes.

32 . The method according to claim 26 , wherein the mixing is at a temperature from about 80° C. to about 110° C.

33 . The method according to claim 26 , wherein the magnetisable material and a filler are mixed prior to addition of the elastomer.

34 . The method according to claim 26 , wherein the sheet in step 2) is formed by passing the mixture produced in step 1) through a dump mill, then onto a sheeting mill and finally onto a three bowl calender for sheeting off.

35 . The method according to claim 26 , further comprising the step of curing the mixture formed in step 1) after the mixture has been formed into the sheet.

36 . The method according to claim 35 , wherein the curing takes place in at least one of a line oven, a microwave oven, or an autovac oven.

37 . The method according to claim 35 , wherein the curing is at a temperature in the range from about 155° C. to about 165° C.

38 . The method according to claim 26 , wherein the sheet has a thickness of from about 0.2 mm to about 6 mm, when in an unexpanded form.

39 . The method according to claim 26 , wherein the sheet formed in step 2) may be laminated to at least one of paperboard, plasterboard, and woven fabrics.

40 . The method according to claim 26 , wherein the material is magnetised.

41 . A fire retardant body comprising the attenuation material according to claims 1 or 25 , and a fire retardant.

42 . A laminate material comprising the attenuation material according to claims 1 or 25 , having bonded thereto a second material, the second material comprising at least one of steel, high performance polymers, PET and aluminium, wherein the high performance polymers comprise polyamides.

43 . The attenuation material according to claim 2 or 3 , wherein the filler material comprises a finely divided form having a particulate size of about 120 microns.

44 . The attenuation material according to claim 4 , wherein the particulate silica comprises waste silica.

45 . The attenuation material according to claim 6 , wherein the magnetisable material is coated with copper.

46 . The attenuation material according to claim 8 , wherein the magnetisable material has a particle size in the range of from about 25 to 400 microns.

47 . The attenuation material according to claim 16 , wherein the vulcanised rubber has a particle size of less than about 120 microns.

48 . The attenuation material according to claim 23 , wherein the polyolefin type rubber comprises an ethylene propylene rubber.

49 . The method according to claim 28 , wherein the mixer has a rotor speed of about 80 rpm.

50 . The method according to claim 26 , wherein the mixture in step 1) is mixed for about 8 minutes.

51 . The method according to claim 26 , wherein step 1) further comprises the matrix of elastomer having mixed therewith a filler.

52 . The method according to claim 26 , wherein at least the magnetisable material, the vulcanised rubber, and a filler are mixed together prior to further mixing with the elastomer, prior to curing or vulcanisation of the elastomer.

53 . The method according to claim 26 , wherein the vulcanised rubber is not added to the elastomer after the addition of the magnetisable material and a filler.

54 . The attenuation material according to claim 5 , wherein the waste silica is from power station lakes.

55 . The attenuation material according to claim 19 , wherein the adhesion enhancing material comprises neoalkoxy zirconate.

56 . The attenuation material according to claim 24 , wherein the magnetisable material comprises at least one of millscale, copper silicate and Fe 3 O 4 .

57 . The method according to claim 30 , wherein the vulcanised rubber is added to the elastomer before addition of the magnetisable material.

58 . The method according to claim 30 , wherein the vulcanised rubber is added to the elastomer at substantially the same time as the magnetisable material.

59 . The method according to claim 44 , wherein the waste silica is from power station lakes.

60 . The method according to claim 53 , wherein the vulcanised rubber is added to the elastomer before addition of the magnetisable material and the filler.

61 . The method according to claim 53 , wherein the vulcanised rubber is added to the elastomer at substantially the same time as the magnetisable material and the filler.

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